Method for manufacturing a metal-ceramic composite structure and metal-ceramic composite structure

Abstract

A method for manufacturing a metal-ceramic composite structure for high temperature exposure is provided, whereby the composite structure includes a base metal structure or component, which is on at least one side covered and permanently joined with one or more ceramic tiles. The method may include the steps of: manufacturing green bodies with cavities and sintering the green bodies to receive ceramic tiles into cavities; arranging the ceramic tiles in a cast mould; pouring liquid metal into the cast mould to substantially fill the cavities; creating an intermediate metal layer; and solidifying the liquid metal to permanently join the ceramic tiles and the intermediate metal layer.

The invention claimed is: 
     
       1. A method for manufacturing a metal-ceramic composite structure having a base metal structure or component, which is on at least one side covered and joined with one or more ceramic tiles, said method comprising:
 a) manufacturing one or more green bodies with cavities extending from a surface on one side of said green bodies into an interior of said green bodies and sintering said green bodies to receive one or more ceramic tiles with respective cavities; 
 b) arranging said one or more ceramic tiles in a cast mould, whereby the one or more ceramic tiles are used as a part of the cast mould; 
 c) pouring liquid metal into said cast mould at a temperature and pressure that said cavities of said one or more ceramic tiles are filled completely or to a great extent in order to fabricate at least one intermediate metal layer to be joined with said base metal structure or component; wherein the at least one intermediate metal layer is created with mechanical interlocks between said one or more ceramic tiles and said at least one intermediate metal layer; 
 d) after solidification of said poured-in metal, taking the resulting metal-ceramic structure with its mechanical interlocks between said one or more ceramic tiles and said at least one intermediate metal layer, out of said cast mould; and said one or more ceramic tiles with said at least one intermediate metal layer are then joined with said base metal structure or component. 
 
     
     
       2. The method as claimed in  claim 1 , wherein the metal used for said base metal structure or component, or said at least one intermediate metal layer, is a Ni-based superalloy. 
     
     
       3. The method as claimed in  claim 1 , wherein step (b) includes assembly and masking of the one or more ceramic tiles using soluble ceramics. 
     
     
       4. The method as claimed in  claim 1 , wherein said cavities in said one or more ceramic tiles are arranged in such a way that most of the ceramic at said mechanical interlocks is under compression during later use over the used temperature range. 
     
     
       5. The method as claimed in  claim 1 , wherein said base metal structure or component is a hot gas path part of a gas turbine. 
     
     
       6. The method according to  claim 5 , wherein said base metal structure or component is a stator heat shield. 
     
     
       7. The method according to  claim 5 , wherein said base metal structure or component is a combustor liner. 
     
     
       8. The method according to  claim 5 , wherein said base metal structure or component is a platform and/or airfoil of a blade and/or vane.